As part of a major compressor station modernization program, three aging gearboxes supporting critical natural gas compression services had reached the end of their service life following multiple failures and repairs. The facility required a replacement solution capable of supporting the transition from natural gas engine-driven compressor trains to electric motors with variable frequency drives (VFDs) while minimizing modifications to existing infrastructure.

Blackstone partnered with Baker Hughes Lufkin Gears to design, supply, and install three NF2507S replacement gearboxes engineered specifically for the upgraded operating requirements. The retrofit optimized compressor throughput based on available motor horsepower, torque, and process demands while minimizing modifications to existing foundations, piping systems, and station infrastructure.

Working within an active operating facility, the project involved detailed engineering, installation, alignment, commissioning, and operational support activities. The completed upgrade enhanced equipment reliability, improved operational flexibility, and positioned the station for long-term performance.

• Design, supply, and install three Baker Hughes Lufkin Gears NF2507S replacement gearboxes  

• Support the transition from natural gas engine drivers to electric motors with VFD controls  

• Engineer the gearbox retrofit to minimize foundation, piping, and station modifications  

• Optimize gearbox performance based on compressor requirements and available motor horsepower and torque  

• Perform installation, alignment, commissioning, and operational support activities  

Western Gear Corporation Model No. 4525THS20-16 (removed & replaced)

• Limited overhead crane capacity within the compressor station required the new gearboxes to be disassembled for installation and reassembled inside the building  

• Modifications to the lubrication oil piping system were required due to differences between the legacy and new gearbox designs  

• Historical piping modifications were not fully documented, requiring additional engineering evaluation during installation  

• Integration of an existing seal oil pump to maintain parts standardization across the pipeline system required collaboration with non-standard suppliers and limited technical documentation  

• Discovery of loose sole plates and grout deterioration beneath one gearbox required additional repair and regrouting activities  

• Existing hold-down stud configurations differed from original design requirements, requiring engineering evaluation and customized solutions to ensure proper installation and thread engagement  

Above: Unit: 101 Retrofit/Installation

Above: Baker Hughes Lufkin Gears Gearbox Model: NF2507S shaft alignment during installation.

Above: Cooper Bessemer Centrifugal Compressor Model: 144RC

• Improved gearbox reliability and availability for critical natural gas transportation operations  

• Increased operational flexibility through the implementation of electric motor drives and VFD technology  

• Optimized compressor throughput while maximizing available horsepower and torque capabilities  

• Enhanced equipment protection through advanced vibration monitoring systems and condition-based maintenance capabilities  

• Early detection of equipment health issues through continuous monitoring, helping reduce the risk of major failures and unplanned outages  

• Reduced repair costs and downtime through improved diagnostics and proactive maintenance planning  

• Extended asset life and improved long-term station performance  

• Strong return on investment through increased reliability, operational efficiency, and reduced lifecycle maintenance costs

This gearbox retrofit project successfully modernized a critical compressor station while minimizing disruption to existing infrastructure and operations. Through close collaboration between Blackstone, Baker Hughes Lufkin Gears, and project stakeholders, the project delivered a reliable, efficient, and future-ready drive system designed to support growing energy demands across the region. 

The success of the project has led to ongoing support activities, including coupling replacements, alignment services, vibration monitoring upgrades, and equipment optimization initiatives. These continued investments further enhance station reliability and demonstrate the long-term value achieved through the modernization program.